This article reviews the dynamic factors, experimental methods and setup, and result analysis of different types of high strain rate shear tests. These include high strain rate torsion testing, double-notch shear testing and punch loading, drop-weight compression shear testing, thick-walled cylinder testing, and pressure-shear plate impact testing.

Film radiography requires the development of the exposed film so that the latent image becomes visible for viewing. It describes the general characteristics of film, including speed, gradient, and graininess, and the factors affecting film selection and exposure time. The article discusses the three major inspection techniques for tubular sections, namely, the double-wall, double-image technique; the double-wall, single-image technique; and the single-wall, single-image technique. It illustrates the arrangements of penetrameters and identification markers for the radiography of plates, cylinders, and flanges. The article discusses various control methods, including the use of lead screens; protection against backscatter and scatter from external objects; and the use of masks, diaphragms, collimators, and filtration. The radiographic appearance of specific types of flaws is also discussed. The article concludes with a discussion on two methods of radiographic film processing: manual and automatic processing.

Control of grain flow is one of the major advantages of shaping metal parts by rolling, forging, or extrusion. This article shows the effects of anisotropy on mechanical properties. Cylindrical forgings commonly have a straight parting line located in a diametral plane. The alternate classes of parting lines are called either "straight" or "broken" for brevity. Regardless of whether draft is applied or natural, the forging will have its maximum spread or girth at the parting line. Proper placement of the parting line ensures that the principal grain flow direction within the forging will be parallel to the principal direction of service loading. The article reviews the mutual dependence of parting line and forging process. It provides a checklist for the forging designer that suggests a systematic approach for establishing parting line location. Finally, the article contains examples, with illustrations of parting line locations, accompanied by tables of design parameters.

The morphology of the graphite particles in compacted graphite iron (CGI) is intermediate to the graphite particles found in gray iron or ductile iron. This article discusses the castability and product design of compacted graphite iron. The introduction of modern measurement and control technologies has made CGI a viable material for high-volume series production. The article describes the production of compacted graphite iron castings and the process control that depends on the production volume of components made from compacted graphite iron. It also discusses the process control for high-volume CGI commonly based on thermal analysis.

Compacted graphite iron (CGI) invariably includes some nodular (spheroidal) graphite particles, giving rise to the definition of the microstructure in terms of percent nodularity. This article discusses the graphite morphology and mechanical and physical properties of CGI. The mechanical and physical properties of CGI with ferritic and pearlitic matrix structures are summarized in a table. The article describes the standards for CGI, with the definition of the grades based on the minimum tensile strength. It also provides information on the applications of compacted graphite iron castings.

Eddy-current inspection is based on the principles of electromagnetic induction and is used to identify or differentiate among a wide variety of physical, structural, and metallurgical conditions in electrically conductive ferromagnetic and nonferromagnetic metals and metal parts. This article discusses the advantages and limitations of eddy-current inspection, as well as the development of the eddy-current inspection process. It reviews the principal operating variables encountered in eddy-current inspection: coil impedance, electrical conductivity, magnetic permeability, lift-off and fill factors, edge effect, and skin effect. The article illustrates some of the principal impedance concepts that are fundamental to understanding of and effective application of eddy-current inspection. It discusses various types of eddy-current instruments, such as the resistor and single-coil system, bridge unbalance system, induction bridge system, and through transmission system. The article concludes with a discussion on the inspection of aircraft structural and engine components.

This article describes the benefits that can be achieved by using thermal spray on particular engine parts of an automobile. These include improvement in fuel consumption, wear resistance and bonding, and reduction of oil consumption, exhaust heat loss, and cooling heat loss. Typical engine parts are cylinder blocks, cylinder bores, cast iron cylinder liners, piston rings, connecting rod bearings, turbochargers, engine valve lifters, exhaust system parts, and oxygen sensors. The article also describes the benefits of using thermal spray on transmission parts such as synchronizer rings and torque converters.

This article focuses on ultrasonic testing (UT) applied to metallic additive manufacturing (AM) parts, presenting the basic principles of UT. It provides a detailed discussion on postprocess UT inspection of powder-bed-fusion-manufactured samples and directed-energy-deposition-manufactured samples.

Oxyfuel gas welding (OFW) is a manual process in which the metal surfaces to be joined are melted progressively by heat from a gas flame, with or without a filler metal. This article discusses the capabilities, advantages, and limitations of OFW. It describes the role of gases, such as oxygen, acetylene, hydrogen, natural gas, propane, and proprietary gases, in OFW. The article discusses the important elements of an OFW system, such as gas storage facilities, pressure regulators, hoses, torches, related safety devices, and accessories. It describes the sequence for setting up a positive-pressure welding outfit. The article provides information on forehand welding and backhand welding, as well as various joints used. It concludes with a discussion on repairs and alterations, as well as the safety aspects.

This article discusses the classifications, specifications, applications and methods for producing welded and seamless steel tubular products, including pipes and tubes. Common types of pipes include standard pipe, conduit pipe, piling pipe, pipe for nipples, transmission or line pipe, water main pipe, oil country tubular goods, water well pipe, and pressure pipe. Pipes in suitable sizes, and most of the products classified as tubing, both seamless and welded, may be cold finished. Pressure tubes are given a separate classification by both the American Society for Testing and Materials (ASTM) and producers. The term tube covers three groups, including pressure tubes, structural tubing, and mechanical tubing.

Machining serves as a more specialized supplement to the forging process, particularly in the formation of cavities and holes. This article provides information on the enclosures, cavities, and holes in hammer and press forgings. It provides a checklist that serves as a guide to the procedure for reviewing the design of cavities and holes to be incorporated in forgings. The article also describes forging designs in which cavities and holes are related to rib and web designs, punchout, piercing, extruding, and combinations of these processes.

This article illustrates the mechanics of the deep drawing of a cylindrical cup. It discusses the fundamentals of drawing and drawability. Sheet metal is drawn in either hydraulic or mechanical presses. The article summarizes the defects in drawing and factors considered in press selection for drawing. It explains the types of dies used for drawing sheet metal and the effects of process variables and material variables on deep drawing. The process variables that affect the success or failure of a deep-drawing operation include the punch and die radii, punch-to-die clearance, press speed, lubrication, and type of restraint of metal flow used. The article describes the process of redrawing and ironing of metals. Drawing of workpieces with flanges and drawing of hemispheres are also illustrated. The article also provides information on the reducing of drawn shells, methods for expanding portions of drawn workpieces, trimming, and deep drawing using fluid-forming presses.

This article illustrates the role that fracture mechanics can play in failure analysis. It describes the important failure criteria as relations between design and materials factors, which are used to correlate fracture mechanics analysis to the observations of a failure analysis. Descriptions include an indication of how the factors are typically evaluated. The article also provides information on subcritical fracture mechanics. Finally, a group of failure analysis examples explain how fracture mechanics parameters can be determined and how they may be fitted into an overall failure investigation.

Torsion tests can be carried out on most materials, using standard specimens, to determine mechanical properties such as modulus of elasticity in shear, yield shear strength, ultimate shear strength, modulus of rupture in shear, and ductility. This article discusses the torsional deformation of prismatic bars of circular cross-section and torsional response of prismatic bars of noncircular cross-section. It analyzes the elastic deformation, plastic deformation, and the effect of strain rate on plastic deformation. The article describes the theory of anisotropy in plastic torsion and the various components of a torsion testing machine. These include drive system, test section, torque and rotational displacement transducers, and rigid frame.

This article focuses on friction, lubrication, and wear of internal combustion engine parts, improvements in which provide important gains in energy efficiency, performance, and longevity of the internal combustion (IC) engine systems. It discusses the types, component materials, and Friction and Wear Control of IC engine. The article explains the process of friction reduction by surface textures or coatings. It provides information on surface hardening of iron and steel, which is commonly employed for engine and powertrain components such as crankshafts, cams, and cylinder liners. The article also discusses advanced surface engineering technologies, such as diamondlike carbon coatings and surface texture technology. Information on thermal-spray methods that have led to improvements in engine components is also provided. The article describes IC engine-components wear, namely, piston assembly wear, valvetrain wear, cylinder-bore wear, and engine bearing wear. It concludes with information on inlet valve and seat wear of IC engine.

The stress-intensity concept is based on the parameter that quantifies the stresses at a crack tip. This article summarizes some stress-intensity factors for various crack geometries commonly found in structural components. Through-the-thickness cracks may be located in the middle of a plate; at the edge of a plate; or at the edge of a hole inside a plate. The article discusses uniform farfield loading in terms of point loading of a center crack and point loading of an edge crack. It tabulates the correction factors for stress intensity at shallow surface cracks under tension. Farfield tensile loading and part-through crack in a finite plate are also discussed. The article concludes with a discussion on through-the-thickness crack and part-through crack in a pressurized cylinder.

This article provides the basics of overall quench process distortion. It describes the influence of quenching processes on the generation of distortion. Examples for the distortion behavior of different types of components are presented. Then, comparisons between different quenching processes are provided. The article presents some possibilities for minimization of shape changes by the quenching process itself. Several suggestions are given for quenching processes in evaporating fluids. An example is provided for out-of-roundness reduction for rings by well-defined inhomogeneous quenching in a gas nozzle field. Another example shows how intensive and high-speed quenching can help to reduce the bending of shafts with an asymmetrical cross-section. The last example shows the result when external loads and nonsymmetric quenching act together. The article also presents test samples for the judgment about distortion potential arising from heat treatment equipment.

The commonly used nondestructive testing of cast products include liquid penetrant inspection, radiographic inspection, fluoroscopic inspection and automated defect recognition, ultrasonic inspection, eddy current inspection, process-controlled resonant testing (PCRT), leak test, and electrical conductivity measurements. This article summarizes the application of these nondestructive tests to castings. It also tabulates a partial list of automotive part types and materials amenable to PCRT and lists the potential limitations to the use of PCRT.

Erosion of a solid surface can be brought about by liquid droplet impingement (LDI), which is defined as "progressive loss of original material from a solid surface due to continued exposure to erosion by liquid droplets." In this article, the emphasis is placed on the damage mechanism of LDI erosion under the influence of a liquid film and surface roughness and on the prediction of LDI erosion. The fundamentals of LDI and processes involved in initiation of erosion are also discussed.

Powder metallurgy compacting presses usually are mechanically or hydraulically driven, but they can incorporate a combination of mechanically, hydraulically, and pneumatically driven systems. This article provides a comparison of mechanical and hydraulic presses based on the cost, production rate, and machine overload protection. The article lists the classification of powder metallurgy parts based on complexity of shapes as suggested by the Metal Powder Industries Federation, such as Class I parts, Class II parts, Class III parts, and Class IV parts. It describes rigid tooling compaction and details the powder-fill ratio considerations for these classes. The article elaborates on the types of tooling systems and presses used for these classes. Some important factors and components used in designing a tool are also described. Finally, the article considers tool materials, including punches, core rods, and punch clamp rings.